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Brake Caliper Rebuild

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    #1

    Brake Caliper Rebuild

    So I put the rear brake caliper back together this afternoon. I tried to follow the guides on Basscliff's Brakes Odds and Ends page but I just wanted the okay from you all if I did this right.

    First, placing the inner seal into caliper:



    Second, place dustcover around piston:



    Third, pour some brake fluid around cylinder of caliper and use wrag/fingers to wipe around. I didn't put fluid between dustcover and piston so please let me know if I need to redo that part.

    Fourth, place piston into caliper and push with hands:



    Finished product. Dust covers looks to be uniformly set around the piston and just slightly above the edge:



    Thank you all for looking. First time doing brakes here so I'm a little nervous. Oh and thanks to my eldest stepdaughter for taking the first three pictures for me.
    Cowboy Up or Quit. - Run Free Lou and Rest in Peace

    1981 GS550T - My First
    1981 GS550L - My Eldest Daughter's - Now Sold
    2007 GSF1250SA Bandit - My touring bike

    Sit tall in the saddle Hold your head up high
    Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
    and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"
    Tags: None
    #2
    Looks good! You are doing fine!

    You have stainless steel / Teflon brake lines for when everything goes back together?
    Ed

    To measure is to know.

    Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

    Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

    Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

    KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

    Comment

      #3
      Great work, just make sure the dust cover boot in pressed into the groove at the top of the cylinder to prevent dirt and moisture from getting in around the piston.

      Comment

        #4
        Yep. Got those in a couple of weeks ago...here's the rear brake line.

        Cowboy Up or Quit. - Run Free Lou and Rest in Peace

        1981 GS550T - My First
        1981 GS550L - My Eldest Daughter's - Now Sold
        2007 GSF1250SA Bandit - My touring bike

        Sit tall in the saddle Hold your head up high
        Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
        and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

        Comment

          #5
          Looks good

          Don't forget the O ring that goes in that LH hole in the last pic when you bolt it back together
          1978 GS 1000 (since new)
          1979 GS 1000 (The Fridge, superbike replica project)
          1978 GS 1000 (parts)
          1981 GS 850 (anyone want a project?)
          1981 GPZ 550 (backroad screamer)
          1970 450 Mk IIID (THUMP!)
          2007 DRz 400S
          1999 ATK 490ES
          1994 DR 350SES

          Comment

            #6
            ARRRGGGGGHHHHHH. I can't find the brake pad shims from my old pads and the new ones don't have them. Does anyone have a spare set they don't want? Or at least know of a suitable replacement I can get somewhere? I'll post this in parts wanted too.
            Cowboy Up or Quit. - Run Free Lou and Rest in Peace

            1981 GS550T - My First
            1981 GS550L - My Eldest Daughter's - Now Sold
            2007 GSF1250SA Bandit - My touring bike

            Sit tall in the saddle Hold your head up high
            Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
            and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

            Comment

              #7
              isnt the dust boot supposed to also be set on the rim of the caliper?

              Comment

                #8
                Originally posted by Adler View Post
                isnt the dust boot supposed to also be set on the rim of the caliper?
                Nope, it sits in the groove shown in photo #3

                He has the piston pushed in too far in photo #4, so the seal is mashed down
                1978 GS 1000 (since new)
                1979 GS 1000 (The Fridge, superbike replica project)
                1978 GS 1000 (parts)
                1981 GS 850 (anyone want a project?)
                1981 GPZ 550 (backroad screamer)
                1970 450 Mk IIID (THUMP!)
                2007 DRz 400S
                1999 ATK 490ES
                1994 DR 350SES

                Comment

                  #9
                  Originally posted by Big T View Post
                  Nope, it sits in the groove shown in photo #3

                  He has the piston pushed in too far in photo #4, so the seal is mashed down
                  That is the groove on the piston, there is another groove on the caliper that the boot is supposed to fit around.

                  Comment

                    #10
                    Originally posted by Big T View Post
                    Nope, it sits in the groove shown in photo #3

                    He has the piston pushed in too far in photo #4, so the seal is mashed down
                    The rear caliper is on the bike now but if I have to remove it it's fine. When you say it's too far down, how far should it be? I think I remember it sitting just below the boot so that I could pull the boot off first before pulling up on the caliper. Will I have problems? If so, what kind?
                    Cowboy Up or Quit. - Run Free Lou and Rest in Peace

                    1981 GS550T - My First
                    1981 GS550L - My Eldest Daughter's - Now Sold
                    2007 GSF1250SA Bandit - My touring bike

                    Sit tall in the saddle Hold your head up high
                    Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
                    and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

                    Comment

                      #11
                      Originally posted by Adler View Post
                      That is the groove on the piston, there is another groove on the caliper that the boot is supposed to fit around.
                      Yes you are correct

                      Comment

                        #12
                        These guys are right, sorry I missed it. See how the boot is sticking up above the piston? It shouldn't. The dust boot needs to engage with a lip on the caliper half. You should be able to get it where it needs to be without too much dissassembly.

                        Oh, and I might have some extra pad shims. Please do me a favor and check the parts fishe to see if they are the same as the shims on a GS1000 caliper.


                        Last edited by Nessism; 09-20-2010, 09:23 AM.
                        Ed

                        To measure is to know.

                        Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                        Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                        Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                        KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                        Comment

                          #13
                          Thanks Ed and others. I'll take the caliper off the bike tonight and fix it.
                          Cowboy Up or Quit. - Run Free Lou and Rest in Peace

                          1981 GS550T - My First
                          1981 GS550L - My Eldest Daughter's - Now Sold
                          2007 GSF1250SA Bandit - My touring bike

                          Sit tall in the saddle Hold your head up high
                          Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
                          and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

                          Comment

                            #14
                            Which is right?

                            So I tried to redo it this morning...which one looks right to you? I am sure the boot is seated around that groove at the top of the piston.



                            Cowboy Up or Quit. - Run Free Lou and Rest in Peace

                            1981 GS550T - My First
                            1981 GS550L - My Eldest Daughter's - Now Sold
                            2007 GSF1250SA Bandit - My touring bike

                            Sit tall in the saddle Hold your head up high
                            Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
                            and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

                            Comment

                              #15
                              There are two lips that it needs to go over....
                              First it needs to slide into the lip on the piston... done
                              Now you need to pull it over the lip on the caliper... See that lip?

                              Comment

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